So far, I've been lurking and enjoying every post.
Let me share a HOLY SH*T!!

Thanks!

This beast is a bit large for fancy face mounts, so we're working on plans for a similarly beastly foot mount. Vinny, the other design guy on the team, wants to build a wooden mock-up motor that we can actually hammer steel around and form a fabricated steel mount that looks like a proper vintage cast iron piece. We'll probably cut about 30 plywood discs on the ShopBot and glue/screw them together for the mock-up/hammer form. Should be fun and, of course, we'll share pics if the madness.

I think most people here know, but for lurkers - it's going in back - mid-motored.

Quote:

Originally Posted by Woodsmith

....Forget hammering steel around plywood, no strength in it. Just use the ply for test fitting, or just use the motor itself for test fitting.

A rolling mill should be better able to roll nice neat hoops as a starting point, or perhaps you can find off cuts of pipe with the right ID to machine to fit.

We have anvils for the serious beating. This would just be for fine-tuning, and as you stated - test fitting, without hoisting a 300lb hunk in and out, and in and out. The wooden mock-up motor and hammering form was Vinny's idea. I want them to exercise their creativity, find out what works, what doesn't, and why - plus, it's a useful piece to have around.

Come to think of it, I should update the CAD mock-up with the 13" monster motor... That will also help me start thinking about what the chassis will look like back there, around the motor.

Tucks in well. I will have to think through rpm range, speed & performance goals, etc, with this motor. We may need some kind of under/over drive gear box between the motor and driveshaft (which would need to be accounted for in the installation).

The green boxes are the battery packs. I didn't put any representation for the controller in yet, as we need to sit down and have a team discussion about our goals with this particular set up, how long we plan to use it, and what the budget is for it...

With the prop shaft that short I'd be thinking of IRS, or deDion tube, or very limited suspension travel.
Looks huge in there.

It was only designed for a couple inches of compression, and maybe an inch of extension, so about three inches total. I have kicked around the idea of IRS, but that solid axle really fits the vintage truck theme better, and the musclecar guys have developed true sports car level handling with one now.

He said, yes, he can make brush-less motors, and it's cheaper and easier to make, and he has the design to do it. Then he hit me with a show-stopping question. He asked what I would do with it if I had one... I had to say, "umm... I guess I would use it for a neat paper weight on my desk."

This is because he knows we had spent weeks of work on the dyno trying to setup examples of the best BLDC controllers in the world to operate on motors setup with low resistance and inductance, and ended up with NOTHING WORKING in a useful way, even with $3,000 controllers and engineers flying out from the controller companies to try to set them up, and still getting garbage performance that the brushed Agni crushed in efficiency, power, torque, torque control, etc.

I hate the idea of spinning copper rather than magnets as much as anyone, but until the controller technology arrives, the brush carrier is a damn efficient, light weight, and robust(when setup correctly) way to get the job done.